Vehicular lighting system having clevis

ABSTRACT

A housing having an extrusion forming a first channel and a second channel; a lighting system in the first channel adapted to direct light away from the first channel; a mounting system in the second channel adapted to couple the extrusion to a vehicle; a first end cap including a first connector, the first end cap being coupled to a first end of the extrusion; a second end cap including a second connector, the second end cap being coupled to a second end of the extrusion; wherein the first connector and the second connector are electrically coupled to one another, and wherein the first connector and the second connector are electrically coupled to the lighting system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/842,411 filed Mar. 15, 2013, which is incorporated in its entiretyherein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to providing auxiliary lightingsystems. More particularly, this invention relates to auxiliary lightingsystems for mobile platforms with an integral mounting system.

2. Discussion of the Related Art

A mounted auxiliary light typically consists of one or more lightsources in a protective housing. The light sources may be of varioustypes, for example light-emitting diode (LED), high-intensity discharge(HID) or halogen. The protective housing comes with or is configured fora mounting system that allows the external mounted light to be securedto a base. The auxiliary light is typically powered by a wiredconnection to a battery, for example a vehicle battery.

A mounted auxiliary light is commonly used where the operator of avehicle requires additional lighting beyond ambient lighting andlighting provided by the vehicle. For example, an off-road vehicle in alocation with no exterior lights may require more lighting than thatprovided by the vehicle's headlights. The auxiliary light may be used inconjunction with, for example, vehicles, aircraft, watercraft,motorcycles, trailers and commercial equipment. The auxiliary light mayalso be used in a stationary location, for example, in an architecturaluse.

A mounted auxiliary light may be mounted to a portion of a vehicle orother structure. Because of the variance of structures and mountinglocations, it is often desirable to have an adaptable mounting systemwhich accommodates varying mounting locations and allows the externalmounted light to rotate about one or more axes.

The user of a mounted auxiliary light may require a cover to, forexample, protect the light or change the type of light emitted. Coversmay be made of, for example, fabric or plastic and may be transparent oropaque.

SUMMARY OF THE INVENTION

Several embodiments of the invention advantageously address the needsabove as well as other needs by providing an auxiliary lighting systemsfor mobile platforms with an integral mounting system.

In one embodiment, the invention can be characterized as a housingcomprising an extrusion forming a first channel and a second channel; alighting system in the first channel adapted to direct light away fromthe first channel; a mounting system in the second channel adapted tocouple the extrusion to a vehicle; a first end cap including a firstconnector, the first end cap being coupled to a first end of theextrusion; a second end cap including a second connector, the second endcap being coupled to a second end of the extrusion; wherein the firstconnector and the second connector are electrically coupled to oneanother, and wherein the first connector and the second connector areelectrically coupled to the lighting system.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features and advantages of severalembodiments of the present invention will be more apparent from thefollowing more particular description thereof, presented in conjunctionwith the following drawings.

FIG. 1 is a perspective view of the front of the light bar system.

FIG. 2 is a perspective view of the rear of the light bar system.

FIG. 3 is a side view of the light bar system.

FIG. 4 is a schematic wiring diagram of in-series connection of lightbar systems.

FIG. 5 is a schematic wiring diagram for a light combination system.

Corresponding reference characters indicate corresponding componentsthroughout the several views of the drawings. Skilled artisans willappreciate that elements in the figures are illustrated for simplicityand clarity and have not necessarily been drawn to scale. For example,the dimensions of some of the elements in the figures may be exaggeratedrelative to other elements to help to improve understanding of variousembodiments of the present invention. Also, common but well-understoodelements that are useful or necessary in a commercially feasibleembodiment are often not depicted in order to facilitate a lessobstructed view of these various embodiments of the present invention.

DETAILED DESCRIPTION

The following description is not to be taken in a limiting sense, but ismade merely for the purpose of describing the general principles ofexemplary embodiments. The scope of the invention should be determinedwith reference to the claims.

Reference throughout this specification to “one embodiment,” “anembodiment,” or similar language means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment of the present invention. Thus,appearances of the phrases “in one embodiment,” “in an embodiment,” andsimilar language throughout this specification may, but do notnecessarily, all refer to the same embodiment.

Furthermore, the described features, structures, or characteristics ofthe invention may be combined in any suitable manner in one or moreembodiments. In the following description, numerous specific details areprovided to provide a thorough understanding of embodiments of theinvention. One skilled in the relevant art will recognize, however, thatthe invention can be practiced without one or more of the specificdetails, or with other methods, components, materials, and so forth. Inother instances, well-known structures, materials, or operations are notshown or described in detail to avoid obscuring aspects of theinvention.

Referring first to FIG. 1, a perspective view of a light bar system 100according to one embodiment of the present invention is shown. Shown isa light bar assembly 102, including a center housing 104, an adjustmenttrack 106, a right end cap 108, a power source wiring 110, a rightreceptacle 112, a left end cap 114, a left receptacle 116, a front cap118, a front lens 120, a light-emitting diode (LED) array 122 (comprisedof a plurality of LED lights 150), and a reflector array 124 (comprisedof a plurality of reflectors 148). Also shown is a mounting assembly126, including an adjustment bracket 128, an adjustment bracket hole130, a clevis 132, a plurality of clevis holes 134, a pivot bolt 136, apivot nut 138, a pivot washer 140, a mounting bolt 142, a mountingwasher 144, a mounting nut 146, an internal wiring system 158, a PCboard, a gasket 160, and a PC board 162. The center housing 104 is achannel-shape, with the top and bottom of the channel forming the topand bottom of the light bar assembly 102. It is made of extruded metalor other suitable material. In one embodiment, the center housing 104 isapproximately 2-3 inches high and 3-5 inches deep. The length of thecenter housing 104 varies with the embodiment of the invention, but inthe preferred embodiment generally varies between 6 inches and 52inches. The back of the center housing 104 is curved and incorporates aplurality of horizontal fins. At the top and bottom of the centerhousing 104 are longitudinal indentations approximately ⅛″ wide and ⅛″deep which may be used to couple an external light cover to the lightbar assembly 102. At the bottom of the back of the center housing 104,two continuous curved horizontal ridges protrude from the center housing104, forming the adjustment track 106. The front portion of the centerhousing 104 is shaped to hold and support the reflector array 124, theLED array 122, front lens 120 and the internal wiring system 158. Thegasket 162 is formed by machine and completely circles the outer edge ofthe front lens 120 where the inside facing outer portion of the frontlens 120 lens meets with an continuous interior indentation of the lightbar assembly 102.

The reflector array 124 size varies depending on the light barvariations. In general, there are one or more reflectors 148 in a row inthe reflector array 124. FIG. 1 represents an embodiment of theinvention with eight reflectors 148 in a row. Each reflector 148 has acurved conical shape and is connected at the wide end by a flat portionof the reflector array 124, similar to the construction of an eggcarton. In one embodiment, there are two horizontal reflector 148 rowsstacked on top of one another. FIG. 1 represents an embodiment of theinvention with a single row in the reflector array 124. The LED light150 is coupled to the PC board 160 and positioned so that the LED light150 extends through a small hole in the narrow end of the reflector 148.The grouping of the LED lights 150 forms the LED array 122. In front ofthe reflector array 124, a thin transparent front lens 120, made ofpolycarbonate or other suitable material, covers the reflector array124. The front lens 120 is transparent so as not to affect thephotometrics of the reflectors 148. The reflector array 124 is coupledto the PC board 160 by screws or other suitable method. The front lens120 is coupled to the front cap 118 which frames the front lens 120 andis coupled to the top and bottom of the center housing 104, to the leftend cap 114 on the left, and the right end cap 108 on the right. Thereflectors 148 in the reflector array 124 may all be of the same type,for example, spot reflectors, or a combination of types of reflectorsmay be used. For example, the reflector array 124 may consist of acombination of flood and spot reflectors. This allows for a variety ofphotometric requirements to be satisfied. The right end cap 108 coversand seals the interior of the light bar assembly 102 on the right-handside. The right end cap 108 contains the right receptacle 112 and, inone embodiment, the power source wiring 110. In another embodiment, thepower source wiring 110 may be removed from the right receptacle 112 andswitched to the left receptacle 116. A receptacle plug 152 would beplaced in the right receptacle 112 for safety and to protect theinternal wiring 158. In another embodiment, when the power source wiring110 is coupled to the left receptacle 116, a connecting wire 154 may beused in the right receptacle 112 to connect the light bar assembly 102to additional light bar assemblies 102 in series. The other end of theconnecting wire 154 would be connected to the receptacle of the adjacentlight bar assembly 102. The left receptacle 116 works in a similar way,and may receive either the power source wiring 110, the connectingwiring 154, or the receptacle plug 152. The right end cap 108 is coupledto the center housing 104 with a plurality of end cap attachment screws156. The left end cap 114 covers and seals the interior of the light barassembly 102 on the left-hand side. The left end cap 114 also containsthe left receptacle 116. The left receptacle 116 works in a similar wayto the right receptacle 112, and may receive either the power sourcewiring 110, the connecting wiring 154, or the receptacle plug 152.

The mounting assembly 126 includes the adjustment bracket 128 that iscoupled to the adjustment track 106 in the back of the center housing104. The adjustment bracket 128 may be moved linearly along the entirelength of the light bar assembly 102 to provide maximum adjustment. Thebottom of the adjustment bracket 128 has an adjustment bracket hole 130that is used to attach it to the clevis 132. The clevis is U-shaped,with the plurality of clevis holes 134, one in each side of the clevis.The pivot bolt 136 goes through one side of the clevis 132, through theadjustment bracket hole 130 and through the other side of the clevis132, where is it secured with the pivot bolt washer 140 and the pivotbolt nut 138. At the bottom of the U-shaped base of the clevis 132 thethreaded mounting bolt 142 extends vertically down from the base of theclevis 132. The mounting bolt is used to mount the light bar system 100to a support. The mounting nut 146 and the mounting washer 144 are usedto secure the mounting bolt 142 to the support. The adjustment bracket128 pivots or rotates about the pivot bolt 136 location, allowing forthe light bar assembly 102 to be adjusted to various angles relative tohorizontal. The operation of the adjustment bracket 128 is described inmore detail below. In addition, the adjustment bracket 128 may bereversed on the adjustment track 106 so that the bottom of theadjustment bracket 128 points upward. This allows for a greater range ofsupport mounting options.

Referring next to FIG. 2, a perspective view of the light bar system 100is shown from the rear. Shown are the center housing 104, the front cap118, the left end cap 114, the right end cap 108, a plurality of end capattachment screws 156, the adjustment track 106, the adjustment bracket128, an adjustment screw 200, the clevis 132, the pivot bolt 136, themounting bolt 142, the mounting washer 144 and the mounting nut 146. Inthis embodiment the right receptacle 112 is shown with the power sourcewiring 110, and the left receptacle 116 is shown with the leftreceptacle plug 152.

Referring next to FIG. 3, an elevation of the right side of the lightbar system 100 is shown. Shown are the front cap 118, the right end cap108, the right receptacle 112, the power source wiring 110, the end capadjustment screws 154, the center housing 104, an engagement block 300,the adjustment bracket 128, the adjustment bracket hole 130, theadjustment track 106, the adjustment screw 200, the clevis 132, theclevis hole 134, the pivot bolt 136, the pivot washer 140, the pivot nut138, the mounting bolt 142, the mounting washer 144, the mounting nut146, a plurality of pivot locking pins 302 and a plurality of pivotlocking depressions 304. As described previously, the adjustment track106 is formed by two continuous curved horizontal ridges protruding fromthe center housing 104. The adjustment bracket 128 fits tightly overeach leg of the adjustment track 106 and extends partly into theadjustment track 106 at the open portion of the adjustment track 106. Inthe inside portion of the adjustment track 106, the trapezoidalengagement block 300 fits in the inside of the adjustment track 106 andis bolted to the adjustment bracket 128, locking the mounting assembly126 in place along the adjustment track 106. When the adjustment screw200 is loosened, the engagement block 300 separates slightly from theadjustment bracket 128 , allowing the mounting assembly 126 to slidealong the adjustment track 106. When the mounting assembly 126 is at thedesired location, the adjustment screw 200 is tightened, causingfriction between the adjustment track 106 and the adjustment bracket 128and the engagement block 300, securing the mounting assembly 126 inplace.

As described above, the adjustment bracket 128 pivots relative to theclevis 132 through use of the pivot bolt 136 which passes through boththe plurality of clevis holes 134 and the adjustment bracket hole 130.The pivot washer 140 has the plurality of small pivot lock pins 302which are coupled to the inside face of the pivot washer 140. In thepreferred embodiment the pivot washer 140 has two pivot lock pins 302,located on opposite sides of the hole of the pivot washer 140. The pivotlock pins 302 extend through corresponding holes in the adjacent clevis132 side and rest in the plurality of pivot locking depressions 304 ofthe adjustment 108, a plurality of end cap attachment screws 156, theadjustment track 106, the adjustment bracket 128, an adjustment screw200, the clevis 132, the pivot bolt 136, the mounting bolt 142, themounting washer 144 and the mounting nut 146. In this embodiment theright receptacle 112 is shown with the power source wiring 110, and theleft receptacle 116 is shown with the left receptacle plug 152.

Referring next to FIG. 3, an elevation of the right side of the lightbar system 100 is shown. Shown are the front cap 118, the right end cap108, the right receptacle 112, the power source wiring 110, the end capadjustment screws 154, the center housing 104, an engagement block 300,the adjustment bracket 128, the adjustment bracket hole 130, theadjustment track 106, the adjustment screw 200, the clevis 132, theclevis hole 134, the pivot bolt 136, the pivot washer 140, the pivot nut138, the mounting bolt 142, the mounting washer 144, the mounting nut146, a plurality of pivot locking pins 302 and a plurality of pivotlocking depressions 304. As described previously, the adjustment track106 is formed by two continuous curved horizontal ridges protruding fromthe center housing 104. The adjustment bracket 128 fits tightly overeach leg of the adjustment track 106 and extends partly into theadjustment track 106 at the open portion of the adjustment track 106. Inthe inside portion of the adjustment track 106, the trapezoidalengagement block 300 fits in the inside of the adjustment track 106 andis bolted to the adjustment bracket 128, locking the mounting assembly126 in place along the adjustment track 106. When the adjustment screw200 is loosened, the engagement block 300 separates slightly from theadjustment bracket 128 , allowing the mounting assembly 126 to slidealong the adjustment track 106. When the mounting assembly 126 is at thedesired location, the adjustment screw 200 is tightened, causingfriction between the adjustment track 106 and the adjustment bracket 128and the engagement block 300, securing the mounting assembly 126 inplace.

As described above, the adjustment bracket 128 pivots relative to theclevis 132 through use of the pivot bolt 136 which passes through boththe plurality of clevis holes 134 and the adjustment bracket hole 130.The pivot washer 140 has the plurality of small pivot lock pins 302which are coupled to the inside face of the pivot washer 140. In thepreferred embodiment the pivot washer 140 has two pivot lock pins 302,located on opposite sides of the hole of the pivot washer 140. The pivotlock pins 302 extend through corresponding holes in the adjacent clevis132 side and rest in the plurality of pivot locking depressions 304 ofthe adjustment bracket 128. The pivot locking depressions 304 are aplurality of shallow depressions in the adjustment bracket 128 arrangedin a circular pattern around the adjustment bracket hole 130. The pivotlocking depressions 304 are located so that the pivot lock pins 302 maysit in differing pivot locking depressions 304 depending on the rotationof the adjustment bracket 128 relative to the clevis 132. When the pivotbolt 136 is tightened, the pivot lock pins 302 are engaged by thecorresponding pivot locking depressions 304 and the angle of the lightbar assembly 102 is locked. When the pivot bolt 136 is loosened, thepivot washer 140 may be moved outward so that the pivot lock pins 302clear the pivot locking depressions 304. The adjustment bracket 128 maythen be rotated relative to the clevis 132 until the pivot lock pins 302line up with alternate pivot locking depressions 304, altering the angleof the light bar assembly 102. When the desired angle is reached, thepivot bolt 136 is tightened, locking the angle of the light bar assembly102.

Referring next to FIG. 4, a schematic wiring diagram for in-seriesconnecting of light bar assemblies is shown.

Referring next to FIG. 5, a schematic wiring diagram for a lightcombination is shown. In the embodiment where there are two rows oflighting. Each row may have a different color of LED lights 150. Insteadof lighting both rows at the same time, the light combination circuitallows for one row of lights to be illuminated while the second row oflight is not. This allows for different colors of light to beilluminated separately within the same light bar assembly 102.

While the invention herein disclosed has been described by means ofspecific embodiments, examples and applications thereof, numerousmodifications and variations could be made thereto by those skilled inthe art without departing from the scope of the invention set forth inthe claims.

What is claimed is:
 1. A vehicular lighting system comprising: a lighthousing comprising: an extrusion forming a first channel and a secondchannel, wherein the second channel is a continuous adjustment track; alighting system in the first channel adapted to direct light away fromthe first channel; a first end cap coupled to a first end of theextrusion; a second end cap coupled to a second end of the extrusion;and at least one mounting assembly coupled to the adjustment track, themounting assembly comprising: an adjustment bracket configured toslidably move along the adjustment track and repositionally clamp to theadjustment track; and a clevis rotationally coupled to an end of theadjustment bracket distal to the adjustment track, an end of the clevisdistal to the adjustment bracket configured to mount to a support, arotational axis of the rotational coupling generally parallel to theextrusion.
 2. The vehicular lighting system of claim 1, the adjustmentbracket further comprising an engagement block removably coupled to theadjustment bracket and configured to fit inside the adjustment track. 3.The vehicular lighting system of claim 1, wherein the adjustment trackextends continuously throughout the entire length of the extrusion. 4.The vehicular lighting system of claim 1, wherein the first end capincludes a first connector and the second end cap includes a secondconnector, wherein the first connector and the second connector areelectrically coupled to each other.
 5. The vehicular lighting system ofclaim 1, wherein the first end cap and the second end cap seal theinterior of the housing.
 6. The vehicular lighting system of claim 1,further comprising a front lens coupled to the first channel, whereinthe front lens seals the interior of the housing.
 7. The vehicularlighting system of claim 1, wherein the lighting system includes a firstlight source and a second light source, wherein the first light sourceand the second light source are adapted to be independently switched onand off so that only the first light source, only the second lightsource or both the first light source and the second light source can beilluminated.
 8. The vehicular lighting system of claim 1, wherein theclevis is U-shaped.
 9. The vehicular lighting system of claim 1, whereinthe clevis is rotationally coupled to the adjustment bracket by a pivotbolt, whereby the pivot bolt forms the rotational axis.
 10. Thevehicular lighting system of claim 1, the adjustment track furthercomprising two continuous curved horizontal ridges.
 11. The vehicularlighting system of claim 1, wherein the rotational coupling of theclevis to the adjustment bracket is rotatable about the rotation axisover a range of at least 100 degrees.
 12. The vehicular lighting systemof claim 2, wherein the engagement block is coupled to the adjustmentbracket with an adjustment screw, wherein the adjustment bracket isfrictionally clamped to the adjustment track when the adjustment screwis tightened, and the engagement block separates slightly from theadjustment bracket when the screw is loosened, thereby allowing theadjustment bracket to slide along the adjustment track while remainingcoupled to the track.
 13. The vehicular lighting system of claim 2,wherein the engagement block contacts an interior portion of theadjustment track and a remainder of the adjustment block contacts anexterior portion of the adjustment track.
 14. The vehicular lightingsystem of claim 4 wherein the first connector is coupled to a powersource.
 15. The vehicular lighting system of claim 4, wherein the firstconnector and second connector are each configured to receive a firstinsert and, upon removal of the first insert, receive a second insertdifferent from the first insert, wherein the first insert and the secondinsert are each selected from the group consisting of power sourcewiring configured to connect the lighting system to a power source,connecting wiring configured to electrically connect the lighting systemto another housing, and a receptacle plug configured to protect thelighting system.
 16. The vehicular lighting system of claim 6, furthercomprising a gasket completely encircling an outer edge of the frontlens where an inside-facing outer portion of the front lens meets with acontinuous interior indentation of the first channel.
 17. The vehicularlighting system of claim 7, the lighting system further comprising: afirst reflector adapted to generate a first beam pattern; a secondreflector adapted to generate a second beam pattern; wherein the firstreflector is adapted to reflect light from the first light source; andwherein the second reflector is adapted to reflect light from the secondlight source.
 18. The vehicular lighting system of claim 9, furthercomprising a pivot washer coupled to an outside face of the clevis bythe pivot bolt passing through the pivot washer, the pivot washerincluding a plurality of pivot lock pins disposed on a face of the pivotwasher juxtaposed with the clevis, the adjustment bracket furtherincluding a plurality of pivot locking depressions configured to seatthe pivot lock pins, whereby the rotational coupling is locked when thepivot lock pins are seated in the pivot locking depressions and thepivot bolt is tightened.
 19. The vehicular lighting system of claim 14wherein the second connector is connected to another lighting system inanother housing.
 20. The vehicular lighting system of claim 18, theplurality of pivot locking depressions arranged in a circular patternsuch that the pivot lock pins may seat in differing pivot lockingdepressions upon rotation of the adjustment bracket relative to theclevis, thereby altering an angle of the adjustment bracket relative tothe clevis.